Polycrystalline diamond cutter with improved abrasion and impact resistance and method of making the same
a technology of polycrystalline diamonds and cutters, which is applied in the field of polycrystalline diamond cutters, can solve the problems of fine grained diamond cutters that will likely fracture in high impact applications, exceed the mechanical properties of inserts, and fail to meet the requirements of high-impact applications, and achieves the effects of slowing the rate of wear, reducing the risk of fracture, and increasing the speed of wear
Inactive Publication Date: 2014-07-29
US SYNTHETIC CORP
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Benefits of technology
This patent text describes an invention of a polycrystalline diamond (PCD) cutter with high impact and abrasion resistance. The invention improves the impact resistance of high abrasion PCD cutters and abrasion resistance of high impact PCD cutters. It also increases the thermal stability of a traditional PCD cutter and improves the impact resistance of a thermally stable cutting element. The invention produces a product with high impact / high abrasion and thermal stability throughout the diamond layer thickness.
Problems solved by technology
It is not unusual that PCD cutters are subjected to conditions down hole that exceed the mechanical properties of the insert and failures occur.
However, following the traditional relationship between abrasion and impact resistance, the fine grained diamond cutter will likely fracture in high impact applications.
The opposite holds true as well as a coarser grained diamond product will hold up well in high impact applications but will dull quickly in abrasive applications.
Historically, a significant disadvantage of the use of these non-conventional catalytic materials is that they have produced free-standing PCD discs that are not attached or easily attachable to a substrate.
Method used
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[0079]This invention is intended, in its present embodiment, for use as a cutting structure on earth boring devices used in oil and gas exploration, drilling, mining, excavating and the like. PDC, Polycrystalline Diamond Cutters, are often used as the cutting structure on these earth boring devices. A common limitation of many prior PCD cutters is most often related to the level of abrasion resistance, impact resistance or thermal stability. The current invention in its numerous embodiments provides PCD cutters that improve the limitations of a typical PCD cutter. The current invention provides a PCD cutter with improved abrasion resistance, impact resistance and thermal stability including a method for manufacture thereof.
[0080]FIG. 1 depicts a PCD cutter of the current invention. The cutter comprises an abrasive layer 101 bonded to a substrate of a less hard material 102. The abrasive layer further includes preformed abrasive bodies 103 sintered together under high temperature / hig...
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Abstract
Disclosed are a high impact / high abrasion cutter and a method for manufacture. The high impact / high abrasion cutter includes a plurality of preformed polycrystalline abrasive bodies sintered under high temperature / high pressure conditions to form an abrasive cutting table. The impact and abrasion resistance of a cutter can simultaneously be improved through forming a cutting table from larger preformed polycrystalline sintered particles formed from finer grain particles. Such a cutter can be manufactured through the steps of preforming the polycrystalline abrasive bodies, forming a mixture of said polycrystalline abrasive bodies and sintering said mixture under high temperature / high pressure conditions.
Description
BACKGROUND OF INVENTION[0001]1. Field of the Invention[0002]This invention relates to polycrystalline diamond (PCD) cutters used primarily in the oil and gas industry for drilling. More specifically, this invention relates to polycrystalline diamond cutting tools and a method for manufacture thereof that includes high abrasion and high impact preformed superhard / superabrasive features that improve the abrasion and impact resistance of a PCD cutter.[0003]2. Description of Related Art[0004]Polycrystalline diamond (PCD) cutters often form the cutting structure of down hole tools, including drill bits (fixed cutter, rollercone and percussion bits) reamers, and stabilizers in the oil and gas industry. A variety of PCD devices, specifically diamond cutting surfaces that include different diamond compositions, diamond layers, and diamond blends or combinations thereof have been described and are well known in the art. Generally, the prior art devices do not have diamond tables comprising a...
Claims
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Login to View More IPC IPC(8): E21B10/46
CPCE21B10/46B22F3/14E21B10/567B22F7/06C22C26/00
Inventor SANI, MOHAMMADBERTAGNOLLI, KENPOPE, ERIC
Owner US SYNTHETIC CORP